Tata Steel SmartFAB (1)

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Build Smart.Build Easy
Industrial Products, Projects EXports
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Evolution of steel reinforcements - Globally
countries have traversed this curve from straight
rebars to Ready to use rebars
Shortage of labour made these countries move
ahead in the maturity curve . But going forward,
stringent timelines would necessitate improving
productivity in reinforcement placement
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Tata Steel has also focussed on providing
construction solutions on steel reinforcements
Tata SteelPioneering Products and Solutions
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What is Welded Wire Fabric (WWF)

• Cold-drawn ribbed wire with electric resistance
  fusion welding
• In square or rectangular grids made from small
  diameter wires
• Bonding with concrete is by mechanical anchorage
  at each welded wire intersection plus anchorage
  due to ribbing.
• Standards IS 1566- Hard drawn steel wire
  fabric for concrete reinforcement with steel
  complying to IS 432--2

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What is Welded Wire Fabric (WWF) Made from Wire
not TMT
Why not TMT TMT has dual core cross-section.
The outer tempered martensite layer gives
required tensile strength to the TMT while the
inner ferrite pearlite core give ductility
property. On welding the strong external layer of
martensite loses its high strength. Why Wire
Rods Wire Rods have uniform microstructure. It
is further cold drawn by pulling through triplex
sets of tungsten carbide rolls to increase the
yield strength to the desired value. The process
ensures proper weldability.
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Dimensional Configuration of Welded Wire Fabric
Max size length x width 6m x 2.2 m
Type A Square 200mm x 200mm
Type B Rectangular 100mm x 200mm
Type D Small Square 100mm x 100mm
Type E Square 150mm x 150mm
Spacing available at interval of 5mm
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Supply of Sm_at_rtFAB Welded Wire Fabric
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Design Configuration of Welded Wire Fabric
Type Wire Spacing Wire Spacing Wire Diameter Wire Diameter Cross-sectional Area Cross-sectional Area Nominal Mass
(mm) (mm) (mm) (mm) (mm2/m) (mm2/m) (kg/m2)
Main Cross Main Cross Main Cross Sheet
A 200 200 7 7 192 192 3.021
200 200 8 8 251 251 3.946
B 100 200 7 7 385 192 4.532
100 200 8 8 503 251 5.919
C 150 200 7 7 257 193 3.525
150 200 8 8 335 252 4.603
D 100 100 7 7 385 385 6.042
100 100 8 8 503 503 7.892
E 150 150 7 7 257 257 4.028
150 150 8 8 335 335 5.261
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Benefits of using Sm_at_rtFAB Welded Wire Fabric

• Steel Savings
• Diameter closer to design
• As per IS 456, Lap length is just spacing 100
  mm, compared to 50D in rebar reinforcements
• Savings because of lesser consumption of binding
  wire

• Man Hours Savings
• Lesser number of labors needed as no marking,
  spacing and cutting of bars at site
• Prefabricated mesh is delivered to site a per
  design leading to early completion of
  reinforcement work

• Effective site management
• Reconciliation easier
• Zero wastage
• Simpler Stocking
• Reduced pilferage
• Easier inspection

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Physical and chemical properties of Welded Wire
Fabric
Desired Chemical composition - C Mn P S
Min 0.03 0.30    
Max 0.22 0.60 0.05 0.05
S P 0.075 Ceq 0.5 S P 0.075 Ceq 0.5 S P 0.075 Ceq 0.5 S P 0.075 Ceq 0.5 S P 0.075 Ceq 0.5
Desired Physical Property Unit Min Value as per IS 432-2 Sm_at_rtFAB properties
UTS N/mm2 570 585
Proof Stress (0.2) N/mm2 480 550
Elongation over gauge length 8D 71/2 10
Shear strength 0.25 times of Ys gtas per IS 1566 with test method of IS 4948. 0.25 times of Ys gtas per IS 1566 with test method of IS 4948. 0.25 times of Ys gtas per IS 1566 with test method of IS 4948.
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Unique Services offered by Tata Steel along with
the product

• Design consultancy through dedicated structural
  consultants
• Supply chain solution from wire rod to mesh at
  site (Fragmented supply exists in the industry)
• Certified test reports of Mesh from accredited
  labs (Not a prevalent practice in industry)
• After sales support e.g. Placement drawing
  services

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Examples of Weldmesh Usage
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Applications of Welded Wire Fabric (WWF)
Housing Commercial
Infrastructure
With modern formwork Walls
Building -Slabs
Gabions Stone walls
Industrial
Precast
Slope Guniting
Flooring
Metros Higher dia F- WWF or Carpet reinforcement
Canal - Lining
Side walk
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Project Flipkart Warehouse Project, Hosur by
AVS for TVS Logistics Consulting Engineers
TCE Tech. used Use of Sm_at_rtFAB for
flooring Benefit Time- 63 , Labour 77
Material Saving 32
62m x 8m Bay Conventional TMT Welded Wire Fabric Savings
No. of people 16 10
Time in Hrs. 8 3 63
Man-hrs 128 30 77
MT used 3.4 2.3 32
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Project KEF Infra - Vaishnavi Signature
Commercial building, Bangalore having G10 2
Basements Tech. used Use of Sm_at_rtFAB along with
Precast Hollow Core Slab with in thin cover
slab Benefit Speed of Construction 3 -4
times faster on adoption of new technologies
2.5 lakh Sqft area completed in 6
months compared to 1.5- 2 years time for similar
construction
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Project Sands Infra IT Office tower, Kochi
SmartCity by Tata Projects Ltd Tech. used
Use of Sm_at_rtFAB over decking sheet in 2 towers
32 Floors Benefit Speed of Construction- 30
- 40 of conventional method
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Project Mantri Energia project,
Bangalore Tech. used Use of Sm_at_rtFAB along
with Tunnel formwork Benefit Speed of
Construction Slab-to-slab time achieved 4 days
6days
Sheets with 11 different sizes were Fabricated
Site Image of Mantri Energia
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WELDED WIRE MESH WITH ROCK BOLT USED ON MINE ROOF
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Actual supplies
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Weldmesh Calculators

• Understanding economics

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Weld mesh Calculators
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Basic Weld mesh Calculator
MW Dia-mm CW Dia-mm MW spacing-mm CW spacing-mm Length -mm Width - mm MW-OH1 MW-OH2 CW-OH1 CW-OH2 No. of MW No. of CW TOTAL IN NOS Wt. in MT Price - Rs/MT Price - Rs/Sq-m Sheet Weight in Kg Kg/m2
8 8 150 150 6000 2100 75 75 75 75 14 40 1000 66.29 59000 310 66.29 5.26
7 7 170 170 6000 2100 75 75 75 75 12 35 1000 45.07 59000 211 45.07 3.58
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Project Savings Weld mesh Calculator
TMT(Rebar) TMT(Rebar) TMT(Rebar) Remarks
Price (Rs per tonne) 47000 (FOR Price)
Labour Cost(Cutting,Bending Placing) (Rs per tonne) 5000 Varies from site to site
Binding Wire Cost (Rs per tonne) 700 10 kg _at_ Rs 70/kg
Working Capital Cost _at_ 12(30 days Stocks) (Rs per tonne) 470  
Wastage _at_ 3( material return _at_ half price) (Rs per tonne) 705 Wastage varies ( 3 to 5)
Total Cost Rs per tonne 53875  
WWF(Welded Wire Fabric) WWF(Welded Wire Fabric) WWF(Welded Wire Fabric)  
Price (Rs per tonne) 59000 (FOR Price)
Labour Cost( Placing) (Rs per tonne) 2500 Varies from site to site
Binding Wire Cost (Rs per tonne) 140 2 kg _at_ Rs 70/kg
Working Capital Cost _at_ 12(15 days Stocks) (Rs per tonne) 291  
Time saving-half _at_ 19.9 of TMT price ( see basis calc) (Rs per tonne) -9333  
Wastage (Rs per tonne) 0  
Total Cost Rs per tonne 52598  
Comparative Steel Requirement Comparative Steel Requirement Comparative Steel Requirement  
Steel Required(TMT)-tonne  mt 66.3 Based on actuals req in Project
Steel Required(Weldmesh)-tonne  mt 45.07 Based on actuals req in Project
Steel Saving(Using Mesh)   32 Based on actual saving of steels
Comparative Costing Comparative Costing Comparative Costing  
Total Cost of TMT  (Rs Lakhs) 35.714  
Total Cost of Mesh  (Rs Lakhs) 23.706  
Project Savings Project Savings Project Savings  
Saving of Steel cost(Using Mesh)  (Rs Lakhs) 12.01  
Saving of Steel cost(Using Mesh)  Rs per tonne 18114  
Effective Cost Saving   34  
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Time Savings Calculation for 10 storey building Time Savings Calculation for 10 storey building Time Savings Calculation for 10 storey building Time Savings Calculation for 10 storey building
Description Unit Traditional WWF
Slab to Slab time ( say Time is halved) Days 14 7
For 10 storey building Days 140 70
Reduction in no. of days ( 140days-70days) Days 70 70
Rental gain _at_ 8 Lakhs/month Rs. Lakhs 19 19
Total reinf used _at_ 5kg/ Sft floor area MT 200  
Value of rebar purchased _at_ 47K/mt Rs. Lakhs 94  
Saving over traditional costing 19 Lakhs/94 Lakhs   19.9 19.9

Total area for a 10-storey building with 4 Apts of 1000 sqft each 40,000 sqft Total area for a 10-storey building with 4 Apts of 1000 sqft each 40,000 sqft Total area for a 10-storey building with 4 Apts of 1000 sqft each 40,000 sqft
Floor rental / month _at_ Rs 20/sqft 40,000 sqft x Rs 20/sqft 8 Lakhs / month Floor rental / month _at_ Rs 20/sqft 40,000 sqft x Rs 20/sqft 8 Lakhs / month Floor rental / month _at_ Rs 20/sqft 40,000 sqft x Rs 20/sqft 8 Lakhs / month 8
Total steel used _at_ 5kg/ Sft floor area 40,000 sqft x 5kg/ Sft 200 MT Total steel used _at_ 5kg/ Sft floor area 40,000 sqft x 5kg/ Sft 200 MT Total steel used _at_ 5kg/ Sft floor area 40,000 sqft x 5kg/ Sft 200 MT
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Galvanised Weld mesh Calculator
Zinc Rate/Kg 230
Dia 5.6
GSM required 120
Zn consumption with 20 wastage 13.10
Cost Heads Expense Items Price for Quotation Price for Quotation
Galvaniser Wire drawing Annealing , Pickling, Fluxing 10500 14114
Galvaniser Galvanising Zinc- xxxx Kg/MT _at_ yyy/- Per Kg 3014 14114
Galvaniser Handling, Testing Misc Overheads 600 14114
Fab. Centre Weldmesh Fabrication FinishingPacking etc 8500 8500
Other Costs Inventory carrying cost- for 2 months inventory 783 1300
Other Costs Yield Loss( Scrap generation 1.4 1.4 Scale loss) 517 1300
Conversion Cost 23914
Wire Rod Price 47000
Logistics Transportation from stk yd to Galvaniser 400 2800
Logistics Transportation from Galvaniser to fabricator 400 2800
Logistics Transportation to Site 2000 2800
Total 73714
With 10 margin 81,085
Add credit cost for 60 days _at_ 12 1,599
Price to be quoted 82,685
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Customers Economics for adoption of WWF -
Higher Price is compensated mainly by Steel, Time
Labour savings
All Figs in Rs./MT
Break-Even costing for customers
Break-even point line
Cost to Customer Rebar WWF
Labour Cost (Cutting,Bending Placing) 10000 5000
Binding Wire Cost ( from 8kg to 2Kg/MT) 500 100
Working Capital Cost 370 205
_at_ 12(30 days Stocks to 15 days) 370 205
Wastage _at_ 3 (Scrap _at_ half price) 555 0

• Customer economics works if the Steel saving with
  WWF usage is more than 9 to 11
• Typical steel saving is in range of 13 to 15
  when TMT design is converted to WWF based design
  .
• The savings due to project time reduction due to
  WWF usage is minimum Rs 6000/MT .

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Welded Wire Fabric is not a new solution !!
WWR is more than 110 year old concept with
history of usage since 1905. Some of the most
iconic buildings in US Empire State Building ,
Rockefeller Centre , J F K International Airport
and thousands of kilometres of US Interstate
Highways are reinforced with WWR. It is even
covered as a Reinforcement option in IS456 ( Cl.
5.6C) Reinforced Concrete Specification ever
since 1964 version. ever since 1964 version.

• Introduction has been delayed in India
• Easier availability of cheap construction labors
• Relatively poor priority of early execution of
  projects due to relatively lower capital costs
  before
• High rate of VAT / Sales tax typically 12 to 15
  on Welded Wire Mesh vis a vis 4-5 on rebars
  manually assembled before, the difference being
  a major cost disadvantage

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Adoption of new construction technologies and
Government regulations are expected to drive
demand for WWF.
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Thank You